Hayat Manufacturing — BOMs, production orders and costing
hayaterp.com ↗Hayat Manufacturing is the opt-in Hayat ERP module for factories — garments and denim, hosiery and knitting, towels and bedding, or any plant that makes items from components. Work centres, bills of materials with routings, production orders with material issue, stage-by-stage progress and output, standard and actual cost with variances, MRP, capacity and job work. Who it is for, who does what, switching it on, demo data and how money reaches the accounts.
Hayat Manufacturing runs the shop floor inside Hayat ERP: what a product is made of (the bill of materials), the steps it goes through (the routing), the production orders that make it, the material issued, the pieces that pass each stage, the finished goods received into stock — and what all of it cost. Stock moves through your normal Inventory and the money through your normal accounts, so the stock ledger, trial balance and supplier balances always match the rest of Hayat.
Who it is for
| You run | What Hayat Manufacturing does for you |
|---|---|
| Garment or denim unit | BOMs of fabric, thread, rivets and labels; a cutting → stitching → washing → finishing → packing routing; pieces in, out and rejected at every stage; stitching or washing sent to a contractor as job work. |
| Hosiery, knitting, towels, bedding | BOMs by weight (yarn kg, GSM) or length (fabric metres), scrap % per component, by-products such as yarn waste with a cost share. |
| Any factory or assembly shop | Multi-level BOMs with sub-assemblies and phantoms, standard cost roll-up, production orders from sales orders, MRP that suggests what to make and what to buy, a capacity warning per machine or line. |
The four textile templates (denim, hosiery, towel, bedding) are examples to start from — you map each line to your own items.
The menu
| Menu item | What it is |
|---|---|
| Manufacturing dashboard | Open, late and in-progress orders, the capacity load for the next 14 days, job work due back |
| Production orders | Every order with status tabs; the order page with materials, stages, output, scrap and cost |
| Bills of materials | BOMs, their versions, routing, standard cost, explosion and where-used |
| MRP plans | Material requirements planning: demand, suggestions, creating orders and a purchase requisition |
| Capacity | Load per work centre per day, red when overloaded |
| Job work | Material sent to contractors and received back with their charges |
| Work centres / Operations | Your machines, lines and sections; the operations they do |
| Manufacturing reports | The seven reports below |
| Manufacturing settings | Defaults, off days and posting accounts (mfg.plan only) |
Who does what
| Permission | Typical person | Can do |
|---|---|---|
| mfg.view | Everyone who works in Hayat Manufacturing | See work centres, BOMs, orders, plans, capacity, job work and the quantity reports. Every other permission needs this one too. |
| mfg.plan | Planner, production engineer | Settings, work centres, operations, BOMs and routings, cost roll-up, MRP plans, demo data, the AI BOM suggestion; issue more than the BOM allows or items not in the BOM. |
| mfg.produce | Production supervisor, store keeper on the floor | Create, release, issue, return, log progress, receive output, record scrap and rework, complete, cancel and reschedule orders; job work. |
| mfg.cost | Cost accountant, finance | The money: the Cost tab and cost sheet, cost columns, closing orders (posting variances), the cost reports and the AI variance explanation. |
Without mfg.cost a user sees quantities only — cost columns are empty, the order has no Cost tab and the cost reports are hidden.
Suggested roles (Settings → Roles): Production Manager (all four), Planner (view + plan), Supervisor (view + produce), Cost Accountant (view + cost). See Roles.
Switch it on
Hayat Manufacturing is opt-in: a new business starts without it, and until it is on every screen says Hayat Manufacturing is not part of your subscription.
- Hayat team (super admin): in admin.hayaterp.com → Subscribers, open the business, tick Hayat Manufacturing under Modules and click Save modules. See Switch modules on or off.
- Business admin: in Settings → Roles give the mfg permissions above to the right roles, and those roles to the users. The menu group Hayat Manufacturing appears at their next screen load.
- Planner: fill the Manufacturing settings, then add work centres, operations and BOMs (BOMs and routings).
Hayat Manufacturing uses what you already have: items and warehouses from Inventory, suppliers from Purchasing (contractors for job work), sales orders from Sales (for MRP) and, if you use it, Quality inspections on output.
Try it with demo data
On an empty Manufacturing dashboard (no work centre, no order), a user with mfg.plan sees Load demo factory (also in Manufacturing settings). It creates a small textile unit: seven work centres, the operations, demo items named MFG-DEMO-…, the four template BOMs with their standard cost rolled up, a draft jeans order, a released back-flushed socks order and an MRP plan that has been run. It needs at least one stock location and runs only while there are no production orders.
Settings
Manufacturing settings (mfg.plan) apply to the whole business:
| Setting | Default | Means |
|---|---|---|
| Back-flush by default | Off | New orders issue materials by themselves as work is logged (see back-flush) |
| QC on output by default | Off | New orders start a quality inspection on every output receipt |
| Over-issue allowed % | 10 | Issuing more than the requirement plus this needs mfg.plan |
| Over-produce allowed % | 5 | An order may put out up to its quantity plus this |
| MRP horizon (days) | 30 | How far ahead MRP looks at sales orders |
| Update item standard cost | Off | A BOM roll-up also writes the unit cost to the item in Inventory |
| Off days | — | Days the factory does not work (planned end dates and capacity skip them) |
| Overdue alerts | On | Notify supervisors about late orders and late job work |
| Posting accounts | see below | Which account each posting uses |
How money reaches the accounts
Hayat Manufacturing keeps no ledger of its own. Stock moves through Inventory (moving average cost), journals through Accounts, contractor charges through Purchasing bills.
| What happens | Stock | Journal |
|---|---|---|
| Material issued (or back-flushed) to an order | Out of the store | Dr Work in progress / Cr Inventory, at stock cost |
| Material returned from an order | Back into the store | Dr Inventory / Cr Work in progress |
| Progress logged on a stage | — | Dr Work in progress / Cr labour, machine and overhead absorbed (minutes × the work centre's rates) |
| Output and by-products received | Into the finished-goods store at standard cost | Dr Inventory / Cr Work in progress |
| Job work sent / returned | To / from the "at contractors" location | — |
| Contractor's charges | — | A Purchasing bill, posted at once: Dr Work in progress (or Inventory) / Cr Accounts payable |
| Order closed | — | Scrap and the material, labour and overhead variances; Work in progress for the order goes to zero |
Hayat Manufacturing adds these accounts to your chart the first time it needs them (under 5000 Cost of Sales). Each can be pointed to another account in the settings.
| Code | Account | Used for |
|---|---|---|
| 1210 | Work in Progress | Cost of open orders |
| 1200 | Inventory | Materials and finished goods |
| 5410 | Production Labour Absorbed | Labour charged to orders (credit) |
| 5420 | Machine Cost Absorbed | Machine hours charged to orders (credit) |
| 5430 | Production Overhead Absorbed | Overhead charged to orders (credit) |
| 5440 | Material Usage Variance | More or less material than the standard |
| 5450 | Labour Efficiency Variance | More or less labour than the standard |
| 5460 | Overhead & Machine Variance | Machine, overhead and job-work cost against the standard |
| 5470 | Production Scrap & Rejection | Rejected pieces at standard cost |
Document numbers: MFO production order, MFI material issue / return, MFR output receipt, MFP MRP plan, MJW job work, MJR job-work receipt. Selling the finished goods is ordinary Sales.
Reports
Manufacturing reports filter by date range (this month by default), item and work centre, and download as CSV.
| Report | Shows | Needs |
|---|---|---|
| Production summary by item | Orders, planned, produced, rejected, rework, completion %, yield %, scrap % | mfg.view |
| Work in progress (value by order) | Open orders: actual cost, value received, WIP value and pieces at each stage | mfg.cost |
| Yield by operation | Pieces in, out, rejected and reworked per operation and work centre | mfg.view |
| Order cost & variances (closed) | Standard and actual unit cost, cost by kind, scrap and the three variances | mfg.cost |
| Material consumption vs standard | Standard quantity, issued, variance and usage % per material | mfg.cost |
| Machine / work-centre utilisation | Available hours, machine and labour hours, utilisation %, output | mfg.view |
| Job work by contractor | Jobs, quantity sent, received, rejected, pending, rejection %, charges | mfg.view |
In Hayat Reports two datasets are added for your own charts: Production orders and Material consumption vs BOM (needs mfg.cost).
Hayat AI (optional, see Settings → AI): Suggest with AI drafts a BOM from a product description, and Explain variance explains a closed order's cost variances in plain words. Only item names, quantities and costs are sent; the AI never saves or posts anything.
Getting started in order
- Fill the Manufacturing settings: off days, the over-issue and over-produce limits, back-flush and QC defaults.
- Add your work centres and operations.
- Make a BOM with its routing for each product, and Roll up its standard cost.
- Create and release a production order, issue materials, log progress and receive output.
- Plan ahead with MRP and capacity, and send work out as job work.
- Give each person a role with the right permission.
Hayat Manufacturing pages
| Page | For |
|---|---|
| BOMs and routings | Work centres, operations, BOMs, components, by-products, routing, templates, versions, standard cost, explosion |
| Production orders and costing | Release, material issue and back-flush, stage progress and WIP, output and QC, scrap and rework, complete, close and variances |
| MRP, capacity and job work | MRP plans and suggestions, creating orders and requisitions, the capacity heat map, contractors and job work |